Claims:We claim:

1. A water canon system for automated three dimensional cleaning of boiler furnace walls (20) while boiler is in operation consisting of features in the form of at least one water gun (1) mounted on either side of said walls (20) which can propel water jets at desired pressure, servo controlled linear X-axis and Z-axis slides (8a, 8b) located close to said walls, said slides can be set to clean specific and desired zones on said furnace wall (20) in the selected sequence, along X-axis and Z-axis by precisely positioning the guns (1) to propel water jets in said zones on said wall (20) as per required pressure and a Control Panel (24) is operatively connected to said features for implementing the working relations between said features based on inputs received manually and/or based on the inputs set.

2. The water canon system as claimed in claim 1, wherein said control panel (24) consists of Programmable Logic Controller (PLC), motor starters, closed loop linear axis servo drives for servo motors (21a, 21b) of said slides (8a, 8b) and variable frequency pump drive (PUMP, VFD) for water pump (3) whereby said guns (1) are positioned by said closed loop servo drives for propelling water jets along X-axis and Z-axis in desired zones of said wall (20), the water pressure of said water jet being set by said variable frequency pump drive (PUMP, VFD), on the basis of X-axis and Z-axis coordinates.

3. The water canon system as claimed in claim 1, wherein said X-axis slide (8a) has servo motor (21a) and encoder and said Z-axis slide (8b) has brake servo motor (21b) and encoder.

4. The water canon system as claimed in claims 1 and 2, wherein said Control Panel (24) is connected with Human Machine Interface (19) by means of FO cable with converter (26), the Control Panel is air conditioned and has Supply air fan (25).

5. The water canon system as claimed in claim 4, wherein said Control Panel (24) is connected to Portable Joystick Panel (11) or LCD touch screen Panel.

6. A method for automated three dimensional cleaning of boiler furnace walls (20) while boiler is in operation applying the water canon system as claimed in claims 1 to 5 comprising:
-selecting either of the guns (1) using the HMI (9) connected to the Control Panel (24) which is operatively connected to the components of the water canon system,
-selecting the X-axis and Z-axis corordinates for setting actual positioning of water jet,
-selecting actual velocity along X-axis and Z-axis,
-selecting the water pressure control by opting for either of linear speed, auto PID and manual speed,
-enabling water pump and solenoid valve operation and starting water canon by pressing the proper buttons,
whereby said servo controlled linear X-axis and Z-axis slides (8a, 8b) located close to furnace walls, precisely position the gun (1) to propel water jet in the desired zone(s) with required pressure one after another, till the stop water canon button is put off manually or as set to be so, automatically.

7. The method as claimed in claim 6, wherein the following facilities are available :
-checking the parameters status,
-checking online graphical representation of the cleaning process,
-water jet position and water pressure indication.

8. The method as claimed in claim 6, wherein it involves selecting manual mode by Joystick or HMI (19), seeing X axis and Z axis actual positions, seeing X and Z axis actual velocities, carrying out water pump operation or carrying out solenoid valve operation.

9. The method as claimed in claim 6, comprising:
-setting the cleaning zones,
-checking number of cleaning zone available in the system,
-setting the desired zones to be cleaned so that the zones are cleaned one after another by default or customizing the sequence of cleaning zones.

10. The method as claimed in claim 6, comprising:
-setting the zones for automatic cleaning,
-entering the coordinates of the selected zone X & Z axis through Joystick/HMI or entering calculated value and pressing the set button,
-entering the end coordinate of the selected zone X & Z axis through Joystick/HMI or entering calculated value and pressing the set button,
-viewing/editing each step as desired.

11. The method as claimed in any of the claims 6 to 10, wherein said method includes
-displaying the status of all inputs and outputs,
-displaying diagnostic staus/error of servo drives,
-displaying system status/error,
-displaying graphical representation of the cleaning process,
-displaying all alarms in ascending order of their occurrence.

12. The method as claimed in claim 6, wherein said method includes displaying all alarms in the ascending order of their occurrence and emergency stopping the operation if needed by pressing the emergency stop button, whereby operation of water canon system ceases immediately.
13. The method as claimed in claim 6, wherein joystick operation comprises:
-selecting Joystick (11) in manual page on the HMI, thereby enabling Joystick (11),
-causing gun movement in up and down, right and left direction with respect to the furnace walls (20),
-checking status of selected gun,
-setting the X-axis, Z-axis co ordinates,
-starting water pump and stopping as needed,
-implementing emergency stopping to cease immediate stopping of water canon system operation if needed.

14. A water canon control system for automated three dimensional cleaning of boiler furnace walls (20) while boiler is in operation comprising a control panel (24) which consists of Programmable Logic Controller (PLC), motor starters, closed loop linear axis servo drives for servo motors (21a, 21b) of X-axis and Z-axis slides (8a, 8b) of said system, located close to furnace walls and variable frequency pump drive (PUMP, VFD) for water pump (3), whereby water guns (1) mounted at least one each on either side of furnace walls (20), which can propel water jets at desired pressure, are positioned by said closed loop servo drives for propelling water jets along X-axis and Z-axis in desired zones of said wall (20) in desired sequence, the water pressure of said water jet being set by said variable frequency pump drive (PUMP, VFD), on the basis of X-axis and Z-axis coordinates.

15. A method for automated three dimensional cleaning of boiler furnace walls (20) while boiler is in operation applying the water canon control system as claimed in claim 14 comprising:
-selecting either of the guns (1) using the HMI (9) connected to the Control Panel (24),
-selecting the X-axis and Z-axis corordinates for setting actual positioning of water jet,
-selecting actual velocity along X-axis and Z-axis,
-selecting the water pressure control by opting for either of linear speed, auto PID and manual speed,
-enabling water pump and solenoid valve operation and starting water canon by pressing the proper buttons,
whereby said servo controlled linear X-axis and Z-axis slides (8a, 8b) located close to furnace walls, precisely position the gun (1) to propel water jet in the desired zone(s) with required pressure one after another, till the stop water canon button is put off manually or as set to be so, automatically.

Dated this 30th day of December, 2020.

(SOUMEN MUKHERJEE)
IN/PA - 214
Applicants’ Agent
, Description:WATER CANON SYSTEM

FIELD OF THE INVENTION

The present invention in general, relates to a water canon system for an automated three dimensional on line cleaning of furnace walls. It also relates to method of such automated cleaning applying the water canon system.

More particularly, the present invention relates to a water canon system and a methodology for automatic cleaning of ash on specific zones on the furnace wall, while the boiler is in operation.

TECHNICAL BACKGROUND OF THE INVENTION

It is known that during combustion process in a boiler, furnace ash is generated from the fuel being introduced. This ash burns at a very high temperature which is beyond fusion temperature in this technology and has high tendency to deposit on furnace walls. If not cleaned over a period of operation, this results in reduction of heat transfer to furnace tubes, in efficient combustion, higher furnace exit gas temperature all resulting into adverse impact on boiler performance.

Since the ash deposition is not uniform on the furnace walls, hence the complete furnace wall is not required to be cleaned every time. Rather, there is a requirement to clean specific areas of the furnace walls.

Hence, to have an effective heat transfer, ash deposition on the furnace wall needs to be removed from the deposited area at regular intervals.
One solution is to stop the boiler, wait for it to cool down and then clean the furnace walls from inside. However, this process takes time and boiler availability is affected.

Accordingly, the need in this field of technology is to implement cleaning of potential ash accumulation zones on the furnace wall, while the boiler is in operation. In that view of the matter, different types of cleaning methods are employed to de slag the deposits and restore the design combustion parameters and processes.

However, majority of them adopt either a timer mode of operation or relies on operator experience. This leads to ineffective cleaning which does not target the areas of the boiler where ash is building up causing tube erosion of tube surfaces over a period of time. This further leads to tube failures and further loss of plant availability.

In the above context, it is known to apply smart sensors to recognize where exactly in the boiler the deposits are in real time and then initiate the proper cleaning device with required intensity based on where the build-up is occurring and when it is occurring. However, this technology apart from being expensive and not user friendly is not commercially viable for smaller units, primarily due to its expensive components.

To overcome the aforesaid problems, the present invention provides a water canon system which is user friendly and cost effective and focuses on automated and sequential cleaning operation of ash in specific zones on the furnace walls while the boiler is in operation. The zones and sequence of cleaning the zones can be set and selected very easily.

The technology very judiciously employs a water canon system in an automated manner, which is run very easily and effectively based on inputs from the user and simultaneously, is capable of selective cleaning of desired zones on the furnace walls in the desired sequence, while the boiler is in operation.

OBJECTIVES OF THE INVENTION

It is the prime objective of the present invention to provide a water canon system which ensure automated and sequential cleaning operation of ash in specific zones on the furnace walls, in the sequence as desired, while the boiler is in operation.

It is a further objective of the present invention to provide a methodology for automated and sequential cleaning operation of ash in specific zones on the furnace walls, in the sequence as desired, while the boiler is in operation.

It is a further objective of the present invention to provide a water canon system which is run very easily, automatically and effectively, based on inputs from the user and simultaneously is capable of selective cleaning of desired zones on the furnace walls in the desired sequence.

It is another objective of the present invention to provide a water canon system which is user friendly and easy to operate and cost effective rendering it commercially viable for smaller units.

How the foregoing objectives are achieved should be clear from the contents of the specification hereinafter.

All through the specification including the claims, the words “boiler furnace”, “furnace walls”, “Control Panel/Unit”, “Servo motors”, “X-axis slides”, “Z-axis slides”, are to be interpreted in the broadest sense of the respective terms and includes all similar items in the field known by other terms, as may be clear to persons skilled in the art. Restriction/limitation, if any, referred to in the specification, is solely by way of example and understanding the present invention.
SUMMARY OF THE INVENTION

Accordingly, the present invention provides a water canon system for automated three dimensional cleaning of boiler furnace walls while boiler is in operation. It consists of features in the form of at least one water gun mounted on either side of said walls which can propel water jets at desired pressure and servo controlled linear X-axis and Z-axis slides located close to said walls. The slides can be set to clean specific and desired zones on said furnace wall in the selected sequence, along X-axis and Z-axis. This is done by precisely positioning the guns to propel water jets in said zones on said wall as per required pressure. A Control Panel is operatively connected to said features for implementing the working relations between said features based on inputs received manually and/or based on the inputs set.

The present invention also provides a method for automated three dimensional cleaning of boiler furnace walls while boiler is in operation applying the water canon system as described hereinabove. The steps comprise selecting either of the guns using the HMI connected to the Control Panel which is operatively connected to the water canon system. Thereafter, the X-axis and Z-axis corordinates are selected for setting actual positioning of water jet. The next step is selecting actual velocity along X-axis and Z-axis followed by selecting the water pressure control by opting for either of linear speed, auto PID and manual speed. Then, water pump and solenoid valve operation are enabled and water canon is started by pressing the proper buttons.

The present invention also provides a water canon control system for automated three dimensional cleaning of boiler furnace walls while boiler is in operation comprising a control panel which consists of Programmable Logic Controller, motor starters, closed loop linear axis servo drives for servo motors of X-axis and Z-axis slides of said system, the slides being located close to furnace walls and variable frequency pump drive for water pump. Thereby, water guns mounted at least one each on either side of furnace walls, which can propel water jets at desired pressure guns, are positioned by said closed loop servo drives for propelling water jets along X-axis and Z-axis in desired zones of said wall in desired sequence. The water pressure of said water jet is set by said variable frequency pump drive, on the basis of X-axis and Z-axis coordinates.

It is also within the scope of the present invention to provide a method for automated three dimensional cleaning of boiler furnace walls while boiler is in operation applying the water canon control system as described hereinabove.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Having described the main features of the invention above, a more detailed and non-limiting description of a preferred embodiment will be given in the following with reference to the drawings.

Figure 1 is a view of the layout of the water canon system of the present invention.
Figure 2 is a block diagram of the water canon system according to the present invention.

Figures 3, 4, 5, 6 and 7 are graphical screens available with the user for running the water canon system under control of the control panel according to the present invention.

Figure 8 is a view of the screen showing the possible alarms displayed in the ascending order of their possible occurrence, while the water canon system of the present invention is in running condition.

DETAILED DESCRIPTION OF THE INVENTION

The following describes a preferred embodiment of the present invention which is for the sake of understanding the invention and non-limiting.

It should be understood that the figures show two boilers, but in practice there can be a plurality of such boiler units and the present invention embodies such plurality of boiler units including variations in the number of components shown and orientation thereof.

In all the figures, like reference numerals represent like features.

The water canon system according the present invention ensures cleaning of desired zones in the desired sequence of furnace walls, while the boiler is in operation.

Referring to figure 1, it is a lay out of water canon system showing all its components. First the basic structure of the water canon system is explained and the functioning and operation of the system, is explained a little later.

As shown in figure 1, the water canon system comprises the following features:

Reference numeral Feature
1 Water gun
2a Cooling/sealing Blower with Manual Damper (27)
2b Cooling/sealing blower standby with Manual Damper (27)
3 Water Pump
4 Pressure Transmitter
5 Solenoid Valve
6 Globe Valve
7 Strainer
8a Linear slide X axis with lubrication system
8b Linear slide Z axis with lubrication system
9 Servo motor servo drive with power cable
10 Local control box with stand
11 Joystick
12 Pressure relief valve
13 Strainer
14 Electrical Cable
15 Air piping
16 Water Piping
17 UPS
18 Porta Cabin
19 19 Human Machine Interface (HMI)
20 Furnace Walls
21a X-axis servo motor and encoder
21b Z-axis brake servo motor and encoder
22 Ball joint with nozzle for water gun
23 Cooling and sealing jacket
24 Air conditioned control panel
25 Supply air fan
26 FO cable with converter
27 Damper
28 Fork assembly with spring for water gun
29 Mounting plate assembly for water gun

CS1…….CS 8 Cables for water canon system per boiler
CS7…….CS 14 Cables for control panel (24) to supply air fan (25)

The connectivities between the components should be clear from figure 1. The following description will further explain how the essential components of the water canon system function.
Referring to figure 1, the water canon system for automated three dimensional cleaning of boiler furnace walls (20) while boiler is in operation has at least one water gun (1) mounted on either side of the walls (20). This can propel water jets at desired pressure. Servo controlled linear X-axis and Z-axis slides (8a, 8b) are located close to said walls. As explained a little later, these slides can be set to clean specific and desired zones on said furnace wall (20), in a desired sequence along X-axis and Z-axis.

The guns (1) are precisely positioned to propel water jets in the zones on the wall (20). A Control Panel (24) is operatively connected to the water canon system for implementing the working relations between the features as discussed above, based on inputs received manually and/or based on pre set inputs.

The control panel (24) consists of Programmable Logic Controller (PLC), motor starters, closed loop linear axis servo drives for servo motors (21a, 21b) of the slides (8a, 8b) and variable frequency pump drive (PUMP, VFD) for water pump (3). Thereby, the guns (1) are positioned by closed loop servo drives for propelling water jets along X-axis and Z-axis in desired zones of said wall (20). The water pressure of the water jet is set by variable frequency pump drive (PUMP, VFD), on the basis of X-axis and Z-axis coordinates.

As stated herein before, X-axis slide (8a) has servo motor (21a) and encoder and the Z-axis slide (8b) has brake servo motor (21b) and encoder. The Air Conditioned Control Panel (24) is connected with Human Machine Interface (19) by means of FO cable with converter (26). The Control Panel (24) is connected to Portable Joystick Panel (11) or LCD touch screen Panel.

The connectivities between the various components of the water canon system according to the present invention, will be further clear from the block diagram of the same as shown in figure 2 which is self explanatory.

Having described the basic structural features of the water canon system, the methodology is now described with reference to figure 1 and figures 3 to 7, whereby the operation will be more clear.

Referring to figure 3, the method for automated three dimensional cleaning of boiler furnace walls (20) while boiler is in operation applying the water canon system comprises selecting either of the guns (1) using the HMI (9) connected to the Control Panel (24) which is operatively connected to the water canon system. Thereafter, the X-axis and Z-axis corordinates are selected for setting actual positioning of water jet. The next step is selecting actual velocity along X-axis and Z-axis. Then, water pump and solenoid valve operation are enabled and water canon is started by pressing the proper buttons.
Thus the servo controlled linear X-axis and Z-axis slides (8a, 8b) located close to furnace walls, precisely position the gun (1) to propel water jet in the desired zone(s) at desired pressure one after another in the selected sequence, till the stop water canon button is put off manually or as set to be so, automatically.

Referring to figure 3, the following facilities are available:
-checking the parameters status,
-checking online graphical representation of the cleaning process,
-water pressure indication.

Now, referring to figure 4, the methodlogy consists of selecting manual mode by Joystick or HMI (19), seeing X axis and Z axis actual positions, seeing X and Z axis actual velocities and carrying out water pump operation or carrying out solenoid valve operation.
With reference to figure 5, the operation of the water canon system is further elaborated. The steps comprise setting of the zones for automatic cleaning by entering the coordinates of the selected zone X & Z axis through Joystick/HMI or entering calculated value and pressing the set button, entering the end coordinate of the selected zone X & Z axis through Joystick/HMI or entering calculated value and pressing the set button, viewing/editing each step as desired.

With reference to figure 6 the setps involved in the methodology consist of selecting the desired zones to be cleaned and the desired sequence. The number of cleaning zones available in the system, are first checked. Then the desired zones to be cleaned are sequenced, so that the zones are cleaned one after another by default. Alternatively, the cleaning sequence of the available zones are customized and entered.

With the help of the HMI (19) connected to the Control Panel (24) it is also possible to display the status of all inputs and outputs, display diagnostic staus/error of servo drives, display system status/error, displaying graphical representation of the cleaning process and display all alarms in ascending order of their occurrence.

The Control Panel (27) operatively connected to the features of the water canon system as elaborated herein before can also implement the following:

Pressure control (Figure 7)
1.Auto & Manual Mode selection
2. Auto Mode with Three Options provided, 1. Linear Speed, 2. Auto PID & 3. Manual Speed
3. Water Pump Operation in Manual mode
4. Water Pump Stop facility in Auto mode
5. Solenoid Valve Operation in Manual mode
6. Solenoid Valve Operation close facility in Auto mode
7. Parameters Monitoring
8. Setting of Co-ordinates vs Pump Speed with Linear curve.

Blower Control
1. Auto & Manual Mode selection
2. Individual Blower Start / Stop in Manual mode
3. Cycle time setting for Auto mode
4. Display Blower Status

Control of Lubrication unit
1.Auto & Manual Mode selection
2. Lubrication motor Start / Stop in Manual mode
3. Setting of Auto Mode ON Time in sec & OFF Time in hours based on which the system will operate Auto mode

Settings Control
1. Set the Joystick Velocity value for X & Z axis
2. Display the Joystick max velocity is 40 mm/sec set in system
3. Set the Absolute/Relative Velocity value for X & Z axis
4. Set Auto Cycle Start Point Pressure value
5. Display Water pressure max limit is 20 bar in system

Referring to figure 8, as a part of the operation of the water canon system it is possible to display all alarms in the ascending order of their occurrence and emergency stopping the operation, if needed by pressing the emergency stop button, whereby operation of water canon system ceases immediately.

As a part of the methodology according to the present invention, joystick operation consists of first of all selecting Joystick (11) in manual page on the HMI, thereby enabling Joystick (11). It can cause gun movement in up and down, right and left direction with respect to the furnace walls (20). The status of selected gun can be checked and the X-axis, Z-axis co ordinates are set. Thereafter water pump (3) is started and stopped as needed. The emergency stopping is implemented to cease immediate stopping of water canon system operation if needed.

According to another aspect of the present of the present invention, there is provided a water canon control system for automated three dimensional cleaning of boiler furnace walls (20) while boiler is in operation comprising a control panel (24) which consists of Programmable Logic Controller (PLC), motor starters, closed loop linear axis servo drives for servo motors (21a, 21b) of X-axis and Z-axis slides (8a, 8b) of said system, located close to furnace walls and variable frequency pump drive (PUMP, VFD) for water pump (3).

Thereby, water guns (1) mounted at least one each on either side of furnace walls (20), which can propel water jets at desired pressure guns (1), are positioned by said closed loop servo drives for propelling water jets along X-axis and Z-axis in desired zones of said wall (20) in desired sequence.

The water pressure of said water jet is set by the variable frequency pump drive (PUMP, VFD), on the basis of X-axis and Z-axis coordinates.

It is also within the scope of the present invention to provide a method for automated three dimensional cleaning of boiler furnace walls (20) while boiler is in operation applying the water canon control system as described herein above comprising:
-selecting either of the guns (1) using the HMI (9) connected to the Control Panel (24),
-selecting the X-axis and Z-axis corordinates for setting actual positioning of water jet,
-selecting actual velocity along X-axis and Z-axis,
-selecting the water pressure control by opting for either of linear speed, auto PID and manual speed,
-enabling water pump and solenoid valve operation and starting water canon by pressing the proper buttons,
whereby, the servo controlled linear X-axis and Z-axis slides (8a, 8b) located close to furnace walls, precisely position the gun (1) to propel water jet in the desired zone(s) with required pressure one after another, till the stop water canon button is put off manually or as set to be so, automatically.

Following are some of the non-limiting advantages of the present invention:
a. User friendly operations
b. Manual and Automatic modes of operation
c. Setting the cleaning zones applying automated pre-set mode or manual entry mode.
d. Auto water jet pressure control at different co-ordinates.
e. Customized zone setting.
f. Customized cleaning zone and cleaning sequence.
g. Online Graphical representation of the cleaning process.
h. Diagnostic facility for fault finding
i. Fast & Easy System configuration and setup
j Cost effective since implementation does not need costly components

It should be clear from the description hereinbefore and the various figures that all the objetives of the present invention have been met. This would be even more clear from the appended claims.

The present invention has been described with reference to a preferred embodiment and some drawings for the sake of understanding only and it should be clear to persons skilled in the art that the present invention includes all legitimate modifications within the ambit of what has been described hereinbefore and claimed in the appended claims.